Modular block retaining wall construction system with spacer plates and methods of manufacture and use

ABSTRACT

A modular block retaining wall construction system with a plurality of spacer plates securely fastened to a plurality of blocks. At least one arm extends (i) from each of the plurality of spacer plates, and (ii) partially into an aperture in the one of the plurality of modular blocks. Each of the plurality of spacer plates includes a plate that is spaced from the one of the plurality of modular blocks via the at least one arm at a predetermined distance, thereby defining a cavity therebetween. In this manner, the cavity can be filled with a predetermined amount of material, e.g., gravel, to facilitating proper drainage of liquid, e.g., water, from the soil and/or other material retained by the retaining wall of the present inventive concept.

BACKGROUND OF THE INVENTION 1. Field of the Invention

The present inventive concept relates generally to a wall construction system, and more particularly, to a retaining wall construction system with a plurality of modular blocks and a plurality of spacer plates, and methods of use and manufacture.

2. Description of the Related Art

Conventional systems and methods for constructing retaining walls suffer from various inefficiencies. Among others, use of conventional methods results in excessive wasted materials and presents a dangerous condition during construction. For instance, it is generally desirable to include draining means, e.g., gravel, on a side of the wall that functions to retain soil and/or other material, thereby facilitating proper drainage of water from the soil and/or other material. When using gravel, the wall is constructed and backfilled with an amount of gravel believed to be sufficient, which often results in use of an excess amount of gravel. Further, prior to being backfilled, a large gap or hole is formed between the wall and the soil and/or other material. Until the hole is filled with gravel and/or soil, people and/or animals may accidentally fall into and become trapped in the hole.

Accordingly, there is a need for a retaining wall construction system with methods of use and manufacture that does not suffer from the limitations of conventional system and methods for constructing walls, prevents waste of materials, does not present any dangerous conditions during construction, has a simple design that is easy to use, and has reproducible methods for manufacture and use.

SUMMARY OF THE INVENTION

The following brief description is provided to indicate the nature of the subject matter disclosed herein. While certain aspects of the present inventive concept are described below, the summary is not intended to limit the scope of the present inventive concept. Embodiments of the present inventive concept provide an inventive concept for a retaining wall construction system, and a method of manufacturing and using such retaining wall construction system. The present inventive concept does not suffer from and remedies the deficiencies of conventional systems and methods such as those previously set forth herein.

The present inventive concept provides, in its simplest form, a retaining wall system having a plurality of modular blocks and a plurality of spacer plates, with each of the plurality of spacer plates operable to be securely fastened to one of the plurality of modular blocks via at least one arm that extends (i) from each of the plurality of spacer plates, and (ii) partially into an aperture in the one of the plurality of modular blocks. Each of the plurality of spacer plates includes a plate that is spaced from the one of the plurality of modular blocks via the at least one arm at a predetermined distance, thereby defining a cavity therebetween. In this manner, the cavity can be filled with a predetermined amount of material, e.g., gravel, to facilitating proper drainage of liquid, e.g., water, from the soil and/or other material retained by the retaining wall of the present inventive concept. The present inventive concept further provides a method of manufacturing the retaining wall system, and a method of using or forming a retaining wall using the retaining wall system.

An object of the present inventive concept is to provide a modular retaining wall system and methods operable to accommodate various applications and design specifications, thereby allowing the system and methods of the present inventive concept to be utilized in any instance where a retaining wall is desired.

Another object of the present inventive concept is to provide a modular retaining wall system and methods that does not present any dangerous conditions during construction thereof.

Another object of the present inventive concept is to provide a modular retaining wall system and methods operable to comply with retaining wall best practices and/or applicable regulations regarding retaining walls and proper drainage requirements.

The aforementioned objects and advantages of the present inventive concept may be achieved by providing a retaining wall system. The system may include a plurality of modular blocks. Each of the plurality of modular blocks may include a receiver. The system may include a plurality of spacer plates. Each of the plurality of spacer plates may be securely fastened to one of the plurality of modular blocks via the receiver. Each of the plurality of spacer plates may include a plate. At least one arm may extend between the plate and into the receiver.

Each of the plurality of modular blocks may be securely fastened to the at least one arm of the one of the plurality of modular blocks via a friction-fit engagement. The at least one arm may include a friction-enhancing element and/or a backstop. The friction-enhancing element and the backstop may be spaced from each other along each of the arms. Each of the plates may include a plurality of apertures extending therethrough. The system may include a space formed between each of the plurality of spacer plates and each of the plurality of modular blocks. The space may define a predetermined volume.

The aforementioned objects and advantages of the present inventive concept may further be achieved by providing a method of manufacturing a retaining wall system. The method may include the step of forming a plurality of spacer plates. Each of the plurality of spacer plates may include a plate and at least one arm extending from the plate. The method may include the step of forming a plurality of modular blocks. Each of the plurality of modular blocks may include a receiver. The method may include the step of securing each one of the plurality of spacer plates to one of the plurality of modular blocks via at least one receiver formed in the one of the plurality of modular blocks.

Each one of the plurality of spacer plates may be secured to one of the plurality of modular blocks via the at least one arm extending between the plate and into the one of the plurality of modular blocks. The at least one arm may define a space with a predetermined volume. The space may be formed between respective ones of the plurality of spacer plates and the plurality of modular blocks.

The at least one arm may include a friction-enhancing element. The at least one arm may include a backstop. The friction-enhancing element and the backstop may be spaced from each other along the at least one arm.

The step of forming the plurality of spacer plates may include the step of securing the at least one arm to the plate. Each of the plurality of plates may include a plurality of apertures extending therethrough.

The aforementioned objects and advantages of the present inventive concept may further be achieved by providing a method of forming a retaining wall using a retaining wall system. The method may include the step of forming a first portion of a retaining wall by placing a first set of modular blocks along a first row. Each of the modular blocks may have a spacer plate secured thereto. Each of the spacer plates may have a plate and at least one arm extending (i) from the plate, and (ii) into a respective one of the modular blocks. The at least one arm may define a space having a predetermined volume between the respective one of the modular blocks and the plate.

The method may include the step of filling a first space defined by the first set of modular blocks. The method may include the step of forming a second portion of the retaining wall by placing a second set of the modular blocks along a second row. The method may include the step of filling a second space defined by the second set of modular blocks. The first space and the second space may be between the plate and the modular block of each one of the first set of modular blocks and the second set of modular blocks. Each of the first space and the second space may have a predetermined volume. The at least one arm may include a friction-enhancing element. The at least one arm may include a backstop. The friction-enhancing element and the backstop may be spaced from each other along the at least one arm. Each of the spacer plates may include a plurality of apertures extending therethrough.

The foregoing and other objects are intended to be illustrative of the present inventive concept and are not meant in a limiting sense. Many possible embodiments of the present inventive concept may be made and will be readily evident upon a study of the following specification and accompanying drawings comprising a part thereof. Various features and subcombinations of the present inventive concept may be employed without reference to other features and subcombinations. Other objects and advantages of this present inventive concept will become apparent from the following description taken in connection with the accompanying drawings, which set forth by way of illustration and example, an embodiment of this present inventive concept and various features thereof.

BRIEF DESCRIPTION OF THE DRAWINGS

A preferred embodiment of the present inventive concept, illustrative of the best mode in which the applicant has contemplated applying the principles, is set forth in the following description and is shown in the drawings.

FIG. 1 is a left side elevation, cross-section view of a modular block wall construction system of the present inventive concept assembled and in use;

FIG. 2 is an exploded, perspective view of a modular block and a spacer plate of the system of FIG. 1, with the modular block and the spacer plate unassembled and prior to use;

FIG. 3 is a perspective view of the modular block and the spacer plate of FIG. 2, with the modular block and the spacer plate assembled to define a cavity therebetween and prior to use;

FIG. 4 is a left side elevation, cross-section view of the modular block and the spacer plate of FIG. 3 taken along 4-4, with the modular black and the spacer plate installed on a ground surface and prior to filling of the cavity; and

FIG. 5 is a left side elevation, cross-section view of the modular block and the spacer plate of FIG. 4, after filling of the cavity.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The following detailed description of the present inventive concept references the accompanying drawings that illustrate specific embodiments in which the present inventive concept can be practiced. The embodiments are intended to describe aspects of the present inventive concept in sufficient detail to enable those skilled in the art to practice the present inventive concept. Other embodiments can be utilized and changes can be made without departing from the scope of the present inventive concept. The following detailed description is, therefore, not to be taken in a limiting sense. The scope of the present inventive concept is defined only by the appended claims, along with the full scope of equivalents to which such claims are entitled.

In this description, references to “one embodiment,” “an embodiment,” or “embodiments,” mean that the feature or features being referred to are included in at least one embodiment of the technology. Separate references to “one embodiment,” “an embodiment,” or “embodiments” in this description do not necessarily refer to the same embodiment and are also not mutually exclusive unless so stated and/or except as will be readily apparent to those skilled in the art from the description. For example, a feature, structure, act, or the like described in one embodiment may also be included in other embodiments, but is not necessarily included. Thus, the present technology can include a variety of combinations and/or integrations of the embodiments described herein.

Turning to the drawings and particularly FIGS. 1-5, a retaining wall system 10 is illustrated. The system 10 includes a plurality of modular blocks 12 and a plurality of spacer plates 14. Each of the plurality of spacer plates 14 is operable to be securely fastened to one of the plurality of blocks 12.

Each of the plurality of blocks 12 including a front surface 20, a rear surface 22 extending parallel to the front surface 20, a top surface 24, a bottom surface 26 extending parallel to the top surface 24, and side surfaces 28 with parallel portions 30 that extend parallel to each other and diverging portions 32 that extend toward each other along divergent planes.

An entirety of the front surface 20 or only a portion of the front surface 20 may include surface ornamentation such as, but not limited to a textured surface, a smooth surface, and/or one or more depictions or designs, thereby advantageously providing an improved aesthetic appearance of the plurality of blocks 20. In the exemplary embodiment, the front surface 20 is planar, with a width of 48 inches and a height of 18 inches, but it is foreseen that the front surface 20 may be otherwise sized and/or shaped without deviating from the scope of the present inventive concept.

The top surface 24 of each of the plurality of blocks 12 includes a cavity 34 operable to receive an element therein, which may be utilized for, among other things, anchoring an adjacent one of the plurality of blocks 12 that is stacked thereon. For instance, it is foreseen that the bottom surface 26 of one or more of the plurality of blocks 12 may include an extension sized and shaped to extend into and nest at least partially within the cavity 34 when the one or more of the plurality of blocks 12 is stacked thereon without deviating from the scope of the present inventive concept. In this manner, the plurality of blocks 12 may be securely stacked on each other and advantageously resist undesired lateral displacement therebetween.

The top surface 24 also includes a shelf 36 extending along a rear-most portion of the top surface 24. The shelf 36 may be utilized for, among other things, further anchoring the adjacent one of the plurality of blocks 12 that is stacked thereon. For instance, the bottom surface 26 of one or more of the plurality of blocks 12 includes at least one ridge 38, which is sized and shaped to extend into and nest at least partially on the shelf 36 when the one or more of the plurality of blocks 12 is stacked thereon. In this manner, the plurality of blocks 12 may be securely stacked on each other and advantageously resist undesired lateral displacement therebetween. It is foreseen that the plurality of blocks 12 may be designed with or without (i) the shelf 36 and the at least one ridge 38, and/or (ii) the cavity 34 and the extension without deviating from the scope of the present inventive concept.

In the exemplary embodiment, the top surface 24 is planar, 48 inches wide and 24 inches long with the cavity 34 centered between the side surfaces 28 and spaced 11.29 inches from the front surface 20, but it is foreseen that the top surface 24 may be otherwise sized and/or shaped without deviating from the scope of the present inventive concept. In the exemplary embodiment, the shelf 36 extends 2 inches perpendicularly into the top surface 24, and 2 inches parallel to the top surface 24, but it is foreseen that the shelf 36 may be otherwise sized and/or shaped without deviating from the scope of the present inventive concept. In the exemplary embodiment, the at least one ridge 38 is two identically sized and shaped ridges, each extending 2 inches perpendicularly from the bottom surface 26, and 3 inches parallel to the bottom surface 26, but it is foreseen that the at least one ridge 38 may only include a single ridge or more than two ridges, and/or be otherwise sized and/or shaped without deviating from the scope of the present inventive concept

The bottom surface 26, in the exemplary embodiment, is planar, 48 inches wide and 24 inches long, but it is foreseen that the bottom surface 26 may be otherwise sized and/or shaped without deviating from the scope of the present inventive concept.

The diverging portion 32 of each of the side surfaces 28 advantageously allows adjacent ones of each of the plurality of blocks 12 to be oriented at a plurality of angles relative to each other, while the front surface 20 of each of the adjacent ones forms a continuous surface without any gap or at least a minimalized gap between the front surfaces 20 of the adjacent ones. In this manner, the plurality of blocks 12 may be stacked next to each other to advantageously form a non-linear or curved retaining wall as well as a linear or straight wall. In the exemplary embodiment, the side surfaces 28 have a height of 18 inches and a length of 14 inches with the parallel portions 30 extending 3 inches from the front surface 20, but it is foreseen that the side surfaces 28 may be otherwise sized without deviating from the scope of the present inventive concept.

The top surface 24 also includes a shelf 36 extending along a rear-most portion of the top surface 24. The shelf 36 may be utilized for, among other things, further anchoring the adjacent one of the plurality of blocks 12 that is stacked thereon. For instance, the bottom surface 26 of one or more of the plurality of blocks 12 includes at least one ridge 38, which is sized and shaped to extend into and nest at least partially on the shelf 36 when the one or more of the plurality of blocks 12 is stacked thereon. In this manner, the plurality of blocks 12 may be securely stacked on each other and advantageously resist undesired lateral displacement therebetween. It is foreseen that the plurality of blocks 12 may be designed with or without (i) the shelf 36 and the at least one ridge 38, and/or (ii) the cavity 34 and the extension without deviating from the scope of the present inventive concept.

The rear surface 22 includes at least one receiver or channel 40 extending into the rear surface 22 and partially through each respective one of the plurality of blocks 12. In the exemplary embodiment, the at least one channel includes two channels, but it is foreseen that the rear surface 22 can include only a single channel or more than two channels without deviating from the scope of the present inventive concept. The at least one channel 40 includes an entrance 42 on the rear surface 22 with an abutment portion 44 of the rear surface 22 entirely surrounding the entrance 42.

In the exemplary embodiment, the rear surface 22 is planar, with a width of 36 inches and a height of 16 inches, which does not include any portion of the shelf 36 or the at least one ridge 38, but it is foreseen that the rear surface 22 may be otherwise sized and/or shaped without deviating from the scope of the present inventive concept. In the exemplary embodiment, a center of the entrance 42 of the at least one channel 40 is spaced 9 inches from the bottom surface 26 without including the at least one ridge 38, and 6 inches from one of the side surfaces 28, but it is foreseen that the entrance 42 of the at least one channel 40 may be otherwise positioned on the rear surface 22 without deviating from the scope of the present inventive concept. In the exemplary embodiment, the at least one channel 40 extends 5 inches into each respective one of the plurality of blocks 12, but it is foreseen that the at least one channel 40 may extend further or may not extend as far without deviating from the scope of the present inventive concept.

Each of the plurality of spacer plates 14 include a plate 60 with an interior-facing surface 62 and an exterior-facing surface 64 extending parallel to the inner surface 62. The surfaces 62, 64 are spaced from each other by a perimeter edge 66. At least one arm 68 extends from the interior-facing surface 62 of each of the plurality of spacer plates 14, and is sized and shaped to be received by the at least one channel 40. In the exemplary embodiment, the at least one arm 68 includes two arms, but it is foreseen that the interior-facing surface 62 can include only a single arm or more than two arms without deviating from the scope of the present inventive concept. The at least one arm 68 includes a friction-enhancing element 70 and a backstop 72 positioned along the at least one arm 68 and spaced from each other along the at least one arm 68. The plate 60 includes a plurality of apertures 74 extending therethrough, which are advantageously operable to allow fluid and/or other small particles to pass through the plate 60.

In the exemplary embodiment, each of the plurality of spacer plates 14 are rectangular with a width of 48 inches and a height of 18 inches, but it is foreseen that the plurality of spacer plates 14 may be otherwise sized and/or shaped without deviating from the scope of the present inventive concept. In the exemplary embodiment, the at least one arm 68 is positioned on the interior-facing surface 62 such that a center of the at least one arm 68 is centered between top and bottom portions of the edge 66 at 9 inches and spaced 12 inches from a nearest side portion of the edge 66, but it is foreseen that the at least one arm 68 may be otherwise positioned on the interior-facing surface 62 without deviating from the scope of the present inventive concept. In the exemplary embodiment, the at least one arm 68 extends 17 inches from the interior-facing surface 62 with the friction-enhancing element 70 spaced 12 inches from the interior-facing surface 62 and the backstop 72 spaced 4 inches from the friction-enhancing element 70, but it is foreseen that the at least one arm 68 may extend further, may not extend as far, and/or the friction-enhancing element 70 and/or the backstop 72 may be otherwise positioned on the at least one arm 68 without deviating from the scope of the present inventive concept.

The system 10 is manufactured by separately forming the plate 60 and the at least one arm 68 via one or more plastic resins, e.g., via injection molding. After formation, the at least one arm 68 is secured to the plate 60, e.g., via an arm receiver in the plate 60, via a friction-fit engagement, an adhesive, and/or the like to form one of the plurality of spacer plates 14. After assembly of the plurality of spacer plates 14, each of the plurality of blocks 12 are formed via a casting material, e.g., concrete, using a casting mold. After each one of the plurality of blocks 12 have been poured, but prior to curing, one of the plurality of spacer plates 14 is inserted into the one of the plurality of blocks 12 until the backstop 72 abuts the abutment portion 44. In this manner, the channel 40 is formed by the at least one arm 68. When each one of the plurality of blocks 12 are completely cured, the one of the plurality of spacer plates 14 are secured therein by the friction-enhancing element 70, i.e., via a friction-fit engagement, and the assembly is ready for use. It is foreseen that the plurality of spacer plates 14 may be made via a single mold, e.g., via injection molding, without deviating from the scope of the present embodiment. It is foreseen that each of the plurality of blocks 12 may be formed around each of the plurality of spacer plates 14, with each of the plurality of spacers positioned in a casting mold prior to introduction of a casting material, without deviating from the scope of the present embodiment.

The system 10 is used by positioning one of the plurality of blocks 12 with one of the plurality of spacer plates 14 on a surface 80, e.g., a ground surface. In most applications, multiple ones of the plurality of blocks 12 with one of the plurality of spacer plates 14 will be positioned next to each other to form a first horizontal row. Next, gravel 82 is added to completely fill a space 84 formed between the interior-facing surface 62 of the plate 60 of the plurality of spacer plates 14 and the rear surface 22 of the plurality of blocks 12. It is foreseen that, depending on the application and how adjacent ones of the plurality of blocks 12 are oriented relative to each other, the gravel 82 will extend into and completely fill a gap formed between the adjacent ones of the plurality of blocks 12. Next, soil and/or other material to-be retained by the system 10 of the present inventive concept is added to completely fill any gap between the exterior-facing surface 64 of the plate 60 of the plurality of spacer plates 14. After filling, additional ones of the plurality of blocks 12 are positioned on one of the plurality of blocks 12 in the first horizontal row, thereby forming a second horizontal row, with the process repeated to form as many horizontal rows as required by the application. Prior to forming additional horizontal rows, the space 84 and any gaps are filled as previously discussed. In this manner, the system 10 does not present any dangerous conditions during construction of the system 10. Further, given the space 84 defined by each of the plurality of spacer plates 14 and each of the plurality of blocks 12 has a predetermined size, a user of the system 10 is advantageously able to calculate volume and better forecast an amount of the gravel 82 required for each application. It is foreseen, however, that the space 84 may be sized smaller or larger, thereby altering the volume, without deviating from the scope of the present inventive concept. In this manner, the system 10 prevents waste of materials while ensuring an ideal amount of the gravel 82 is utilized for proper drainage of water from the soil and/or other material.

Having now described the features, discoveries and principles of the general inventive concept, the manner in which the general inventive concept is constructed and used, the characteristics of the construction, and advantageous, new and useful results obtained; the new and useful structures, devices, tools, elements, arrangements, parts and combinations, are set forth in the appended claims.

It is also to be understood that the following claims are intended to cover all of the generic and specific features of the general inventive concept herein described, and all statements of the scope of the general inventive concept which, as a matter of language, might be said to fall there between. 

1. A retaining wall system comprising: a plurality of modular blocks, each of the plurality of modular blocks including a receiver; and a plurality of spacer plates, each of the plurality of spacer plates operable to be securely fastened to one of the plurality of modular blocks via the receiver, each of the plurality of spacer plates including (i) a substantially planar plate, (ii) at least one arm extending between the plate and into the receiver to define a space between the plate and the one of the plurality of modular blocks, and (iii) a plurality of apertures extending through the plate to permit drainage of fluid therethrough.
 2. The retaining wall system of claim 1, wherein, each of the plurality of modular blocks are securely fastened to the at least one arm of the one of the plurality of modular blocks via a friction-fit engagement.
 3. The retaining wall system of claim 1, wherein, the at least one arm includes a friction-enhancing element and a backstop.
 4. The retaining wall system of claim 3, wherein, the friction-enhancing element and the backstop are spaced from each other along each of the arms.
 5. The retaining wall system of claim 1, wherein, the plurality of apertures form an array extending substantially across an entirety of each of the plurality of spacer plates.
 6. The retaining wall system of claim 1, wherein, the space defines a predetermined volume.
 7. A method of manufacturing a retaining wall system, the method comprising the steps of: forming a plurality of spacer plates, each of the plurality of spacer plates including a (i) substantially planar plated, (ii) and at least one arm extending from the plate, and (iii) a plurality of apertures extending through the plate to permit drainage of fluid therethrough; forming a plurality of modular blocks, each of the plurality of modular blocks including a receiver; and securing each one of the plurality of spacer plates to one of the plurality of modular blocks via at least one receiver formed in the one of the plurality of modular blocks, wherein, each of the at least one arms defines a space between respective ones of the plurality of spacer plates and the plurality of modular blocks.
 8. The method of claim 7, wherein, each one of the plurality of spacer plates is secured to one of the plurality of modular blocks via the at least one arm extending between the plate and into the one of the plurality of modular blocks.
 9. The method of claim 7, wherein, each of the spaces defines a predetermined volume between the ones of the plurality of spacer plates and the plurality of modular blocks.
 10. The method of claim 7, wherein, the at least one arm includes a friction-enhancing element.
 11. The method of claim 10, wherein, the at least one arm includes a backstop, and the friction-enhancing element and the backstop are spaced from each other along the at least one arm.
 12. The method of claim 7, wherein, the step of forming the plurality of spacer plates includes the step of securing the at least one arm to the plate.
 13. The method of claim 7, wherein, the plurality of apertures form an array extending substantially along an entirety of each of the plurality of spacer plates.
 14. A method of forming a retaining wall using a retaining wall system, the method comprising the steps of: forming a first portion of a retaining wall by placing a first set of modular blocks along a first row, each of the modular blocks having a spacer plate secured thereto, each of the spacer plates having a substantially planar plate and at least one arm extending (i) from the plate, and (ii) into a respective one of the modular blocks, the at least one arm defining a space having a predetermined volume between the respective one of the modular blocks and the plate, each of the spacer plates having a plurality of apertures extending through the plate to permit drainage of fluid therethrough; filling a first space defined by the first set of modular blocks; forming a second portion of the retaining wall by placing a second set of the modular blocks along a second row; and filling a second space defined by the second set of modular blocks, wherein, the first space and the second space are between the plate and the modular block of each one of the first set of modular blocks and the second set of modular blocks.
 15. The method of claim 14, wherein, each of the first space and the second space has a predetermined volume.
 16. The method of claim 14, wherein, the at least one arm includes a friction-enhancing element.
 17. The method of claim 16, wherein, the at least one arm includes a backstop, and the friction-enhancing element and the backstop are spaced from each other along the at least one arm.
 18. The method of claim 14, wherein, the plurality of apertures form an array extending substantially across an entirety of each of the plurality of spacer plates.
 19. The retaining wall system of claim 1, wherein, the plurality of spacer plates are formed of one or more plastic resins.
 20. The method of claim 14, further comprising the step of: filling a third space on an opposite side of the plate from the first space or the second space with soil, wherein, the first space and the second space is filled with gravel. 